Volkswagen Golf Variant / Jetta. Manual - part 533

 

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Volkswagen Golf Variant / Jetta. Manual - part 533

 

 

148

1

Input Shaft

⇒ “1.1 Input Shaft, Disassembling and Assembling”, page 149

1.1

Input Shaft, Disassembling and Assem‐

bling

Special tools and workshop equipment required
♦ Press Plate - VW401-
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW407-
♦ Press Piece - Multiple Use - VW412-
♦ Press Piece - 60mm - VW415A-
♦ Press Piece - Shift Rod/Alternator - VW422-
♦ Press Piece - Multiple Use Spacer Sleeve - VW472/2-
♦ Press Piece - 42mm - VW516-
♦ Press Piece - Multiple Use - 30-23-
♦ Press Piece - Press Tube - 30-100-
♦ Press Piece - T10080-
♦ Press Piece - T10081-
♦ Circlip Pliers - VW161A-
♦ Press Piece - Trailing arm - 2010-
♦ Press Piece - Block - T10083-
♦ Press Piece - Block - Washer - T10083/1-
♦ Bearing Installer - Bearing Press Plate - T10084A-
♦ Puller - Kukko Internal - 28-37mm - 21/5-
♦ Puller - Kukko Counterstay - 22/1-
♦ Inductive Heater - VAS6414-
♦ -Feeler Gauge-

Note

When install new drive gears. Refer to the technical data. Refer to

⇒ “1.2 Codes, Transmission Allocation and Capacities”, page 2

 and the Parts Catalog.

Insert all bearings, selector gears and synchronizer rings on input shaft with transmission fluid.

Do not exchange synchronizer rings, always allocate to original selector gear when reusing.

Wearing safety gloves, warm the needle bearing sleeve, the gear wheels and the synchronizer hubs to

approximately 100 °C (212 °F) using an Inductive Heater - VAS6414- before installing them.

1. Input Shaft    

149

❑ Replace after removing
❑ Selecting thickness. Re‐

fer to 

⇒ page 125

 .

2 - Locking Collar with 5th Gear

Synchronizer Hub

❑ Removing and instal‐

ling. Refer to

⇒ “6.6 Disassembly and

Assembly Sequence”,

page 117

 .

❑ Disassembling. Refer to

⇒ Fig. ““Locking Collar

and 5th Gear Synchron‐

izer Hub, Disassem‐

bling and Assembling”“ ,

page 157

 .

❑ Assembling 5th gear

locking collar/synchron‐

izer hub. Refer to

⇒ Fig. ““5th Gear Lock‐

ing Collar/Synchronizer

Hub Assembly”“ ,

page 157

❑ Installation position. Re‐

fer to

⇒ Fig. ““Locking Collar

and 5th Gear Synchron‐

izer Hub, Disassem‐

bling and Assembling”“ ,

page 157

 .

3 - 5th Gear Synchronizer Ring

❑ Checking for wear. Re‐

fer to

⇒ Fig. ““Checking Syn‐

chronizer Ring for

Wear”“ , page 154

4 - 5th Gear Wheel
5 - Needle Bearing

❑ For 5th gear
❑ Replace together with -item 6- 

⇒ Item 6 (page 150)

6 - Sleeve

❑ For the 5th gear needle bearing
❑ replace together with -item 5- 

⇒ Item 5 (page 150)

❑ Remove with bearing mount/grooved ball bearing. Refer to

⇒ Fig. ““Remove the Bearing Mount and Grooved Ball Bearing”“ , page 152

❑ Installing. Refer to 

⇒ Fig. ““Install the 5th Gear Needle Bearing Sleeve -A-.”“ , page 156

7 - Transmission Housing
8 - Bearing Mount with Grooved Ball Bearing

❑ Only replace grooved ball bearing together with bearing mount
❑ if bearing mount is removed from transmission housing, it must always be replaced
❑ Removing. Refer to 

⇒ Fig. ““Remove the Bearing Mount and Grooved Ball Bearing”“ , page 152

❑ Installing. Refer to 

⇒ page 155

9 - Input Shaft
10 - Needle Bearing

❑ For 3rd gear

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11 - 3rd Gear Wheel
12 - 3rd Gear Synchronizer Ring

❑ Checking for wear. Refer to 

⇒ Fig. ““Checking Synchronizer Ring for Wear”“ , page 154

13 - Locking Sleeve with Synchronizer Hub for 3rd and 4th Gears

❑ Removing with the 3rd gear wheel. Refer to

⇒ Fig. ““Removing the Bearing Inner Race for the Cylindrical Roller Bearing”“ , page 153

❑ Disassembling. Refer to

⇒ Fig. ““Disassembling and Assembling Locking collar and Synchronizer Hub for 3rd/4th Gears”“ , page

153

 .

❑ Installed position: locking collar/synchronizer hub. Refer to

⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears”“ , page 153

❑ Assembling. Refer to

⇒ Fig. ““Assembling Locking Collar/Synchronizer Hub for 3rd and 4th Gears.”“ , page 153

❑ Installing. Refer to

⇒ Fig. ““Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears”“ , page 154

14 - 4th Gear Synchronizer Ring

❑ Checking for wear. Refer to 

⇒ Fig. ““Checking Synchronizer Ring for Wear”“ , page 154

15 - 4th Gear Wheel
16 - Sleeve

❑ For the 4th gear needle bearing
❑ replace together with -item 17- 

⇒ Item 17 (page 151)

❑ Removing with the 3rd gear wheel. Refer to

⇒ Fig. ““Removing the Bearing Inner Race for the Cylindrical Roller Bearing”“ , page 153

❑ Installing. Refer to 

⇒ Fig. ““Install the 4th Gear Needle Bearing Sleeve -A-.”“ , page 154

17 - Needle Bearing

❑ For 4th gear
❑ replace together with -item 16- 

⇒ Item 16 (page 151)

18 - Thrust Washer
19 - Bearing inner race for the cylindrical roller bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the Bearing Inner Race for the Cylindrical Roller Bearing”“ , page 153

❑ Installing. Refer to

⇒ Fig. ““Installing the Bearing Inner Race -A- for the Cylindrical Roller Bearing”“ , page 154

20 - Circlip

❑ Replacing
❑ Selecting thickness. Refer to 

⇒ Fig. ““Selecting the Locking Ring”“ , page 155

 .

21 - Cylindrical Roller Bearing

❑ With circlip
❑ Removing. Refer to 

⇒ Fig. ““Remove the Roller Bearing from the Clutch Housing”“ , page 152

❑ Installing. Refer to 

⇒ Fig. ““Pressing Cylindrical Roller Bearing into Clutch Housing.”“ , page 152

❑ Installed position: the circlip in bearing points to input shaft

22 - Clutch Housing
23 - Spring

❑ Installation position. Refer to

⇒ Fig. ““Assembling Locking Collar/Synchronizer Hub for 3rd and 4th Gears.”“ , page 153

 .

24 - Locking Collar for 3rd and 4th gear
25 - Synchronizer Hub for 3rd and 4th Gear
26 - Locking Pieces

❑ Quantity: 3

1. Input Shaft    

151

 

 

 

 

 

 

 

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